Automatic Transmission: Other Subaru Outback BP

CAUTION

1. Wear working clothing, including a cap, protective goggles, and protective shoes during operation.
2. Remove contamination including dirt and corrosion before removal, installation, and disassembly.
3. Keep the disassembled parts in order and protect them from dust or dirt.
4. Until the oil pan is installed, do not place with the oil pan inside facing up to prevent foreign matter from entering the valve body.
5. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement.
6. When disassembling the case and other light alloy parts, use a plastic hammer to open the case. Do not pry it apart with a screwdriver or other tool.
7. Be careful not to burn your hands, because each part on the vehicle is hot after running.
8. Use SUBARU genuine gear oil, grease etc. or the equivalent. Do not mix gear oil, grease etc. with that of another grade or from other manufacturers.
9. Be sure to tighten bolts and nuts to the specified torque.
10. Place shop jacks or safety stands at the specified points.
11. Apply appropriate gear oil or ATF onto sliding or revolving surfaces before installation.
12. Replace deformed or otherwise damaged snap rings with new ones.
13. Before installing O-rings or oil seals, apply sufficient amount of ATF fluid to avoid damage and deformation.
14. Be careful not to incorrectly install or fail to install O-rings, snap rings and other such parts.
15. Before securing a part on a vise, place cushioning material such as wood blocks, aluminum plate, or shop cloth between the part and the vise.
16. Avoid damaging the mating surface of the case.
17. Before applying sealant, completely remove the old seal.

Scheme 443

Scheme 444

Scheme 445

Scheme 446

Scheme 447

Scheme 448

Scheme 449

Scheme 450

Scheme 451

Scheme 452

Scheme 453

Scheme 454

Scheme 455

1. SPECIAL TOOLS
2. GENERAL PURPOSE TOOLS

MEASUREMENT

Note. If the clutch or the brake shows a sign of slippage or shifting sensation is not correct, the line pressure should be checked.

Scheme 456

Scheme 457

Scheme 458

Scheme 459

1. Excessive shocks during upshifting or shifting takes place at a higher point than under normal circumstances, may be due to the line pressure being too high.
2. Slippage or inability to operate the vehicle may, in most cases, be due to loss of oil pressure for the operation of the clutch, brake or control valve. Line pressure measurement (under no load) Before measuring the line pressure, jack-up all wheels. Maintain the temperature of ATF at approx. 70 - 80°C (158 - 176°F) during measurement. (ATF will reach the above temperature after idling the engine for approx. 30 minutes with select lever in "N" or "P".) Line pressure measurement (under heavy load) Before measuring the line pressure, apply both foot and parking brakes with all wheels chocked (Same as for "stall" test conditions). Measure the line pressure when select lever is in "R", "2" with engine under stall conditions. Measure the line pressure within 5 seconds after shifting the select lever to each position. (If line pressure needs to be measured again, allow the engine to idle, and then stop it to cool down for at least one minute.) Maintain the temperature of ATF at approx. 70 - 80°C (158 - 176°F) during measurement (ATF will reach the above temperature after idling the engine for approx. 30 minutes with the select lever in "N" or "P".) Temporarily attach the ST to a suitable place in the driver's compartment, remove the blind plug located in front of the toe board and pass the hose of the ST to engine compartment. Remove the test plug and install the ST instead. Connect the ST1 with ST2. ST1 498897200 OIL PRESSURE GAUGE ADAPTER ST2 498575400 OIL PRESSURE GAUGE ASSY Check for duty ratio changes by opening and closing the throttle valve using SUBARU Select Monitor.
3. Non-TURBO model
4. TURBO model

Scheme 460

Scheme 461

Scheme 462

Scheme 463

1. MPT MODEL Check the transfer clutch pressure in accordance with the following chart in the same manner as with line pressure. Refer to «LINE PRESSURE TEST»(ref-208395-S40911946302005120700000) . ST 498897700 OIL PRESSURE ADAPTER SET ST 498575400 OIL PRESSURE GAUGE ASSY AWD mode: "D" range FWD mode: "P" range, engine speed 2,000 RPM NOTE: Before setting in FWD mode, install the spare fuse on FWD mode switch. NOTE: If oil pressure is not produced or if it does not change in the AWD mode, the transfer duty solenoid or transfer valve assembly may be malfunctioning. If oil pressure is produced in the FWD mode, the problem is similar to that in the AWD mode.
2. VTD MODEL Check transfer clutch pressure using the following chart. Refer to «LINE PRESSURE TEST»(ref-208395-S40911946302005120700000) .

Scheme 464

Scheme 465

Scheme 466

Scheme 467

Scheme 468

Scheme 469

Scheme 470

Scheme 471

Scheme 472

Scheme 473

Scheme 474

Scheme 475

Scheme 476

Scheme 477

Scheme 478

Scheme 479

Scheme 480

Scheme 481

Scheme 482

Scheme 483

1. Set the vehicle on a lift.
2. Open the front hood fully, and support it with stay.
3. Disconnect the battery ground cable.
4. Remove the air intake duct. (Non-TURBO model) Refer to «REMOVAL»(ref-208359-S04615035932005120700000) , Air Intake Duct.
5. Remove the air cleaner case or air intake chamber. (Non-TURBO model) Except 2.5 L U5 model Refer to «REMOVAL»(ref-208359-S22811893822005120700000) , Air Cleaner Case. 2.5 L U5 model Refer to «REMOVAL»(ref-208368-S17829489362005120700000) , Air Intake Chamber. 3.0 L models Refer to «REMOVAL»(ref-208384-S00783995372005120700000) , Air Intake Chamber.
6. Remove the intercooler. (TURBO model) Refer to «REMOVAL»(ref-208374-S37358976142005120700000) , Intercooler.
7. Remove the air cleaner case stay. (Non-TURBO model)
8. Disconnect the following connectors. Transmission harness connector Transmission ground terminal
9. Remove the starter. 2.5 L model Refer to «REMOVAL»(ref-167805-S27941158102004102100000) , Starter. 3.0 L model Refer to «REMOVAL»(ref-167805-S27941158102004102100000) , Starter.
10. Remove the pitching stopper.
11. Separate the torque converter clutch from drive plate. Remove the V-belt cover. Remove the service hole plug. Remove the bolts which hold torque converter clutch to drive plate. Insert the wrench in the crankshaft pulley bolts, and remove all the bolts by slowly rotating the crankshaft pulley. CAUTION: Be careful not to drop the bolts into torque converter clutch housing.
12. Install the ST to torque converter clutch case.
13. Remove the ATF level gauge. NOTE: Plug the opening to prevent an entry of foreign particles into transmission fluid.
14. Set the ST. ST 41099AA000 ENGINE SUPPORT ASSY
15. Remove the bolts which hold the right upper side of transmission to engine. Except 3.0 L model 3.0 L model
16. Lift-up the vehicle.
17. Remove the under cover.
18. Remove the front, center and rear exhaust pipe, and muffler. (Non-TURBO model) Except 2.5 L U5 model Refer to «REMOVAL»(ref-208361-S23577908762005120700000) , Front Exhaust Pipe and «REMOVAL»(ref-208361-S17585007752005120700000) , Rear Exhaust Pipe and «REMOVAL»(ref-208361-S00413986862005120700000) , Muffler. 2.5 L U5 model Refer to «REMOVAL»(ref-208369-S08506783432005120700000) , Front Exhaust Pipe. Refer to «REMOVAL»(ref-208369-S20556856332005120700000) , Rear Exhaust Pipe. Refer to «REMOVAL»(ref-208369-S22475579312005120700000) , Muffler. 3.0 L model Refer to «REMOVAL»(ref-208386-S34843623222005120700000) , Front Exhaust Pipe. Refer to «REMOVAL»(ref-208386-S03690047052005120700000) , Rear Exhaust Pipe. Refer to «REMOVAL»(ref-208386-S40817313242005120700000) , Muffler.
19. Remove the center and rear exhaust pipes, and muffler. (TURBO model) Refer to «REMOVAL»(ref-208376-S32454258812005120700000) , Center Exhaust Pipe and «REMOVAL»(ref-208376-S32454258812005120700000) , Rear Exhaust Pipe and «REMOVAL»(ref-208376-S18819972022005120700000) , Muffler.
20. Remove the heat shield cover. (If equipped)
21. Drain ATF to remove the ATF drain plug.
22. Disconnect the ATF cooler hoses from pipes of transmission side, and remove the ATF level gauge guide.
23. Remove the propeller shaft. .
24. Remove the shift select cable. Refer to «REMOVAL»(ref-208392-S29959540702005120700000) , Select Cable.
25. Disconnect the stabilizer link from transverse link.
26. Remove the bolt securing ball joint of transverse link to housing.
27. Remove the spring pins and separate the front drive shafts from each side of transmission. (Non-TURBO model)
28. Pull the front drive shaft out of transmission. (TURBO model) Face the "AT" letter stamped to transmission side. Insert the ST between transmission and front drive shaft. NOTE: Put the projection of ST on torque converter clutch housing. While holding the joint portion of front drive shaft with your hand, push the housing outside to prevent AAR side of boot from stretching, and then remove the front drive shaft from transmission.
29. Remove the securing bolt of clutch housing cover.
30. Remove the nuts which hold the lower side of transmission to engine. Except 3.0 L model 3.0 L model
31. Place the transmission jack under transmission. NOTE: Put cloth between the support plates of transmission jack and the oil pan.
32. Remove the transmission rear crossmember from vehicle.
33. While lowering transmission gradually, tighten engine support fully and tilt the engine backward.
34. Remove the transmission. CAUTION: Move the transmission and torque converter as a unit away from engine.
35. Separate the transmission assembly and rear cushion rubber.

Scheme 484

Scheme 485

Scheme 486

Scheme 487

Scheme 488

Scheme 489

Scheme 490

Scheme 491

Scheme 492

Scheme 493

Scheme 494

Scheme 495

Scheme 496

Scheme 497

Scheme 498

Scheme 499

Scheme 500

1. Replace rear differential side oil seal with new one. (TURBO model) NOTE: If new oil seal is installed, it is not necessary to replace it.
2. Install the rear cushion rubber to transmission assembly. Tightening torque: 39 N.m (4.0 kgf.m, 29 ft.lb)
3. Install the ST to torque converter clutch case.
4. Install the transmission onto engine. Gradually raise the transmission with transmission jack. Engage them at splines. While lifting transmission gradually, turn the screw of engine support and tilt the engine forward.
5. Install the transmission rear crossmember. Tightening torque: T1: 35 N.m (3.6 kgf.m, 26 ft.lb) T2: 70 N.m (7.1 kgf.m, 51 ft.lb)
6. Take off the transmission jack.
7. Tighten the nuts and bolts which hold the lower side of transmission to engine. Tightening torque: 50 N.m (5.1 kgf.m, 36.9 ft.lb) Except 3.0 L model 3.0 L model
8. Install clutch housing cover.
9. Lower the vehicle.
10. Connect the engine and transmission. Remove the ST from torque converter clutch case. NOTE: Be careful not to drop the ST into torque converter clutch case when removing ST. ST 498277200 STOPPER SET Install the starter. Refer to «INSTALLATION»(ref-167805-S28872000082004102100000) , Starter. Tighten the bolts which hold the right upper side of transmission to engine. Tightening torque: 50 N.m (5.1 kgf.m, 36.9 ft.lb) Except 3.0 L model 3.0 L model
11. Install the torque converter clutch to drive plate. Tighten the bolts which hold the torque converter clutch to drive plate. Insert the wrench in the crankshaft pulley bolts, and tighten all the bolts by slowly rotating the crankshaft pulley. Tightening torque: 25 N.m (2.5 kgf.m, 18.1 ft.lb) Clog the plug onto service hole. Install the V-belt cover.
12. Remove the ST.
13. Install the pitching stopper. Tightening torque: T1: 50 N.m (5.1 kgf.m, 37 ft.lb) T2: 58 N.m (5.9 kgf.m, 43 ft.lb)
14. Lift-up the vehicle.
15. Install the front drive shaft into transmission. (Non-TURBO model) Lift-up the vehicle. Install the front drive shaft into transmission. Drive a new spring pin into chamfered hole of drive shaft.
16. Set ST to side retainer. (TURBO model)
17. Align front drive shaft splines with differential bevel gear splines, insert drive shaft, and remove the ST. (TURBO model) ST 28399SA010 OIL SEAL PROTECTOR
18. Push the front housing to securely insert the front drive shaft into the transmission. (TURBO model)
19. Insert the ball joint into housing.
20. Connect the stabilizer link to transverse link, and tighten the bolts. NOTE: Discard the loosened self-locking nut and replace with a new one. Tightening torque: T1: 30 N.m (3.1 kgf.m, 22.4 ft.lb) T2: 50 N.m (5.1 kgf.m, 37 ft.lb)
21. Install the shift select cable onto select lever. Refer to «INSTALLATION»(ref-208392-S10507222842005120700000) , Select Cable.
22. Install the ATF level gauge guide, and connect the ATF cooler hoses to pipe.
23. Install the propeller shaft. .
24. Install the heat shield cover. (If equipped)
25. Install the rear exist pipe and muffler assembly. Non-TURBO model Except 2.5 L U5 model Refer to «INSTALLATION»(ref-208361-S21912926732005120700000) , Rear Exhaust Pipe and «INSTALLATION»(ref-208361-S41100021962005120700000) , Muffler. 2.5 L U5 model Refer to «INSTALLATION»(ref-208369-S39698120092005120700000) , Rear Exhaust Pipe and «INSTALLATION»(ref-208369-S32210117812005120700000) , Muffler. 3.0 L model Refer to «INSTALLATION»(ref-208386-S39855252692005120700000) , Rear Exhaust Pipe and «INSTALLATION»(ref-208386-S35967598162005120700000) , Muffler. TURBO model Refer to «INSTALLATION»(ref-208376-S18278122642005120700000) , Rear Exhaust Pipe and «INSTALLATION»(ref-208376-S42649748292005120700000) , Muffler.
26. Install the front and center exhaust pipe. (Non-TURBO model) Except 2.5 L U5 model Refer to «INSTALLATION»(ref-208361-S07815720742005120700000) , Front Exhaust Pipe. 2.5 L U5 model Refer to «INSTALLATION»(ref-208369-S07988211032005120700000) , Front Exhaust Pipe. 3.0 L model Refer to «INSTALLATION»(ref-208386-S00455349232005120700000) , Front Exhaust Pipe.
27. Install the center exhaust pipe. (TURBO model) Refer to «INSTALLATION»(ref-208376-S19898573452005120700000) , Center Exhaust Pipe.
28. Install the under cover.
29. Lower the vehicle.
30. Install the ATF level gauge.
31. Connect the following connectors. Transmission harness connectors Transmission ground terminal
32. Connect the cruise control cable.
33. Install the air cleaner case stay. Tightening torque: 16 N.m (1.6 kgf.m, 11.6 ft. lb)
34. Install the air cleaner case or air intake chamber. (Non-TURBO model) Refer to «INSTALLATION»(ref-208359-S26990629822005120700000) , Air Cleaner Case.
35. Install the air intake duct. (Non-TURBO model) Refer to «INSTALLATION»(ref-208359-S30669962782005120700000) , Air Intake Duct.
36. Install the intercooler. (TURBO model) Refer to «INSTALLATION»(ref-208374-S16471822542005120700000) , Intercooler.
37. Connect the battery ground cable.
38. Fill ATF by using the gauge hole. Refer to «AUTOMATIC TRANSMISSION FLUID»(ref-208395-S35776238372005120700000) .
39. Take off the vehicle from lift arms.
40. Check select lever operation. Refer to «INSPECTION»(ref-208395-S12298355632005120700000) .
41. Check the ATF level. Refer to «AUTOMATIC TRANSMISSION FLUID»(ref-208395-S35776238372005120700000) .
42. Perform the advance operation of learning control. (TURBO model) Set select lever to "P" range and apply parking brake, then lift up the vehicle. Connect Subaru Select Monitor to vehicle and turn on the switch. Select "Clear Memory - 2" on the SUBARU Select Monitor. Refer to «CLEAR MEMORY MODE»(ref-208399-S29872298192005120700000) , OPERATION, Subaru Select Monitor. Using Subaru Select Monitor, check that the DTC is not output. Refer to «READ DIAGNOSTIC TROUBLE CODE (DTC)»(ref-208399-S08944030632005120700000) , OPERATION, Subaru Select Monitor. Using Subaru Select Monitor, warm up the engine until the ATF temperature becomes within 60 to 90°C (140 to 194°F). . Shift the select lever to the "R" range. Set the switches for headlights, air conditioner, rear defogger, etc. to OFF. Turn the ignition switch OFF and then wait for more than 30 seconds. If the message "communication impossible" is displayed on SUBARU Select Monitor, depress the brake pedal deeply with left foot until the learning promotion task is completed, and then turn the ignition switch to ON. Check that Subaru Select Monitor is operating properly now. Set the select lever to "P" range, and then wait for more than three seconds. Set the select lever to "R" range, and then wait for more than three seconds. Set the select lever to "N" range, and then wait for more than three seconds. Set the select lever to "D" range, and then wait for more than three seconds. Set the select lever to "N" range, and then wait for more than three seconds. Slowly depress the accelerator pedal to the fully open position. Slowly release the accelerator pedal to the fully closed position. Start and idle the engine. Set the select lever to "D" range. Learning promotion task starts. ATF temperature warning light in the combination meter blinks at 2 Hz. If ATF temperature does not blink, turn the ignition switch OFF and repeat the procedure from step 4). Learning promotion task is completed when blinking of ATF temperature warning light in the combination meter changes from 2 to 0.5 Hz. NOTE: Repeat the procedure from step 4) if blinking of AFT temperature warning light changes from 2 to 4 Hz. Set the select lever to "N" range, and turn the ignition switch to OFF.
43. Check the road test. Refer to «ROAD TEST»(ref-208395-S41651055592005120700000) .

Scheme 501

Scheme 502

1. PITCHING STOPPER Remove the air cleaner case or intake chamber. (Non-TURBO model) Except 2.5 L U5 model Refer to «REMOVAL»(ref-208359-S22811893822005120700000) , Air Cleaner Case. 2.5 L U5 model Refer to «REMOVAL»(ref-208368-S17829489362005120700000) , Air Intake Chamber. 3.0 L model Refer to «REMOVAL»(ref-208384-S00783995372005120700000) , Air Intake Chamber. Remove the intercooler. (TURBO model) Refer to «REMOVAL»(ref-208374-S37358976142005120700000) , Intercooler. Remove the pitching stopper.
2. TRANSMISSION REAR CROSSMEMBER AND REAR CUSHION RUBBER Disconnect the ground cable from battery. Jack-up the vehicle and support it with sturdy racks. Remove the front, center, rear exhaust pipes and muffler. (Non-TURBO model) Except 2.5 L U5 model Refer to «REMOVAL»(ref-208361-S23577908762005120700000) , Front Exhaust Pipe and «REMOVAL»(ref-208361-S17585007752005120700000) , Rear Exhaust Pipe and «REMOVAL»(ref-208361-S00413986862005120700000) , Muffler. 2.5 L U5 model Refer to «REMOVAL»(ref-208369-S08506783432005120700000) , Front Exhaust Pipe and «REMOVAL»(ref-208369-S20556856332005120700000) , Rear Exhaust Pipe and «REMOVAL»(ref-208369-S22475579312005120700000) , Muffler. 3.0 L model Refer to «REMOVAL»(ref-208386-S34843623222005120700000) , Front Exhaust Pipe and «REMOVAL»(ref-208386-S03690047052005120700000) , Rear Exhaust Pipe and «REMOVAL»(ref-208386-S40817313242005120700000) , Muffler. Remove the center and rear exhaust pipes, and muffler. (TURBO model) Refer to «REMOVAL»(ref-208376-S32454258812005120700000) , Center Exhaust Pipe and «REMOVAL»(ref-208376-S18574141742005120700000) , Rear Exhaust Pipe and «REMOVAL»(ref-208376-S18819972022005120700000) , Muffler. Remove the heat shield cover. (If equipped) Set the transmission jack under the transmission. Make sure that the support plates of transmission jack don't touch the oil pan. Remove the transmission rear crossmember. Remove the rear cushion rubber.

Scheme 503

Scheme 504

1. PITCHING STOPPER Install the pitching stopper. Tightening torque: T1: 50 N.m (5.1 kgf.m, 37 ft.lb) T2: 58 N.m (5.9 kgf.m, 43 ft.lb) Install the air cleaner case or air intake chamber. (Non-TURBO model) Except 2.5 L U5 model Refer to «INSTALLATION»(ref-208359-S26990629822005120700000) , Air Cleaner Case. 2.5 L U5 model Refer to «INSTALLATION»(ref-208368-S21026510882005120700000) , Air Intake Chamber. 3.0 L model Refer to «INSTALLATION»(ref-208384-S25696994432005120700000) , Air Intake Chamber. Remove the intercooler. (TURBO model) Refer to «INSTALLATION»(ref-208374-S16471822542005120700000) , Intercooler.
2. TRANSMISSION REAR CROSSMEMBER AND REAR CUSHION RUBBER Install the rear cushion rubber. Tightening torque: 39 N.m (4.0 kgf.m, 29 ft.lb) Install the crossmember. Tightening torque: T1: 35 N.m (3.6 kgf.m, 26 ft.lb) T2: 70 N.m (7.1 kgf.m, 51 ft.lb) Remove the transmission jack. Install the heat shield cover. (If equipped) Install the front, center, rear exhaust pipes and the muffler. (Non-TURBO model) Except 2.5 L U5 model Refer to «INSTALLATION»(ref-208361-S07815720742005120700000) , Front Exhaust Pipe and «INSTALLATION»(ref-208361-S21912926732005120700000) , Rear Exhaust Pipe and «INSTALLATION»(ref-208361-S41100021962005120700000) , Muffler. 2.5 L U5 model Refer to «INSTALLATION»(ref-208369-S07988211032005120700000) , Front Exhaust Pipe and «INSTALLATION»(ref-208369-S39698120092005120700000) , Rear Exhaust Pipe and «INSTALLATION»(ref-208369-S32210117812005120700000) , Muffler. 3.0 L model Refer to «INSTALLATION»(ref-208386-S00455349232005120700000) , Front Exhaust Pipe and «INSTALLATION»(ref-208386-S39855252692005120700000) , Rear Exhaust Pipe and «INSTALLATION»(ref-208386-S35967598162005120700000) , Muffler. Install center and rear exhaust pipes, and muffler. (TURBO model) Refer to «INSTALLATION»(ref-208376-S19898573452005120700000) , Center Exhaust Pipe and «INSTALLATION»(ref-208376-S18278122642005120700000) , Rear Exhaust Pipe and «INSTALLATION»(ref-208376-S42649748292005120700000) , Muffler.

PROCEDURE

1. Set the select lever to "P" range and apply parking brake, then lift-up the vehicle.
2. Connect the SUBARU Select Monitor to vehicle.
3. Using SUBARU Select Monitor, check that the DTC is not output. Refer to «OPERATION»(ref-208399-S13840447952005120700000) , Subaru Select Monitor.
4. Using SUBARU Select Monitor, check that ATF temperature is less than 60°C (140° F). Refer to «OPERATION»(ref-208399-S13840447952005120700000) , Subaru Select Monitor.
5. Set the SUBARU Select Monitor to OFF.
6. Set the ignition switch to OFF.
7. With pressing shift lock release button, set the select lever to "R" range.
8. Depress the brake pedal fully with left foot until air bleeding is complete.
9. Turn the ignition switch to ON.
10. Set the select lever to "P" range, and then wait for more than three seconds.
11. Set the select lever to "R" range, and then wait for more than three seconds.
12. Set the select lever to "N" range, and then wait for more than three seconds.
13. Set the select lever to "D" range, and then wait for more than three seconds.
14. Set the select lever to "N" range, and then wait for more than three seconds.
15. Slightly depress the accelerator pedal to full open.
16. Slightly release the accelerator pedal to close.
17. Start the engine.
18. Set the select lever to "D" range.
19. Turn the SUBARU Select Monitor power to ON.
20. On the SUBARU Select Monitor, select the "individual system inspection" of main menu.
21. On the "individual system inspection" selection menu, select the "individual system inspection" and air bleeding of control valve will start in transmission. At this time, ATF temperature warning light in the combination meter blinks at 2 Hz. If ATF temperature warning light does not blink, repeat the procedure from step 4).
22. Air bleeding of control valve is completed when blinking of ATF temperature warning light in the combination meter changes from 2 Hz to 0.5 Hz. NOTE: Repeat the procedure from step 4) if blinking of ATF temperature warning light changes from 2 Hz to 4 Hz during air bleeding.
23. Set the select lever to "N" range, and turn the ignition switch to OFF.
24. Set the select lever to "P" range to finish air bleeding.

Scheme 505

Scheme 506

Scheme 507

1. SHIFT SOLENOIDS AND DUTY SOLENOIDS Lift-up the vehicle. Clean the transmission exterior. Replace the gasket with a new one, and tighten the drain plug. Drain the ATF completely. Tightening torque: 25 N.m (2.5 kgf.m, 18.1 ft.lb) Remove the oil pan. Disconnect the solenoid and duty solenoid connectors. Remove the solenoids and duty solenoids.
2. ATF TEMPERATURE SENSOR For removal of ATF temperature sensor, refer to «REMOVAL»(ref-208395-S30259546762005120700000) .

Scheme 508

Scheme 509

Scheme 510

Scheme 511

Scheme 512

1. SHIFT SOLENOIDS AND DUTY SOLENOIDS Insert solenoid and duty solenoid to specified position. Tighten the bolts and nuts. Tightening torque: 8 N.m (0.8 kgf.m, 5.8 ft.lb) Connect the harness connectors. Connect the connectors of same color, and secure the harness to valve body using clips. Apply proper amount of liquid gasket to the entire oil pan mating surface. Fluid packing: THREE BOND 1217B (Part No. K0877YA020) Apply liquid gasket fully to three holes other than screw holes on transmission case. Fluid packing: THREE BOND 1217B (Part No. K0877YA020) Tighten bolts evenly and install the oil pan. Tightening torque: 5 N.m (0.5 kgf.m, 3.6 ft.lb) Refill with the same amount of ATF that was drained. Check the ATF level. Refer to «AUTOMATIC TRANSMISSION FLUID»(ref-208395-S35776238372005120700000) .
2. ATF TEMPERATURE SENSOR For installation of ATF temperature sensor, refer to «INSTALLATION»(ref-208395-S10476214332005120700000) .

Scheme 513

Scheme 514

Scheme 515

Scheme 516

Scheme 517

Scheme 518

Scheme 519

1. Set the vehicle on a lift.
2. Disconnect the ground cable from battery.
3. Remove the air cleaner case or air intake chamber. Except 2.5 L U5 model Refer to «REMOVAL»(ref-208359-S22811893822005120700000) , Air Cleaner Case. 2.5 L U5 model Refer to «REMOVAL»(ref-208368-S17829489362005120700000) , Air Intake Chamber. 3.0 L model Refer to «REMOVAL»(ref-208384-S00783995372005120700000) , Air Intake Chamber.
4. Remove the pitching stopper.
5. Remove the front exhaust pipe with center exhaust pipe. (Non-TURBO model)
6. Refer to «REMOVAL»(ref-208361-S23577908762005120700000) , Front Exhaust Pipe.
7. Remove the rear exhaust pipe and muffler. Except 2.5 L U5 model Refer to «REMOVAL»(ref-208361-S17585007752005120700000) , Rear Exhaust Pipe and «REMOVAL»(ref-208361-S00413986862005120700000) , Muffler. 2.5 L U5 model Refer to «REMOVAL»(ref-208369-S20556856332005120700000) , Rear Exhaust Pipe and «REMOVAL»(ref-208369-S22475579312005120700000) , Muffler. 3.0 L model Refer to «REMOVAL»(ref-208386-S03690047052005120700000) , Rear Exhaust Pipe and «REMOVAL»(ref-208386-S40817313242005120700000) , Muffler.
8. Raise the vehicle and drain the ATF.
9. Remove the heat shield cover. (If equipped)
10. Remove the propeller shaft. .
11. Remove the transmission rear crossmember. Support the transmission using a transmission jack and raise it slightly. Remove the bolts and nuts as shown in the figure.
12. Remove the rear vehicle speed sensor.
13. Remove the select cable nut.
14. Move the gear select cable so that extension bolts can be removed.
15. Remove the bolts.
16. Remove the extension case. NOTE: Use a container to catch oil flowing from extension.
17. Disconnect the transfer duty solenoid connector.
18. Remove the transfer duty solenoid and transfer valve body.

Scheme 520

Scheme 521

Scheme 522

Scheme 523

Scheme 524

1. Install the transfer duty solenoid and transfer valve body. Install the transfer duty solenoid and transfer valve body. Tightening torque: T: 8 N.m (0.8 kgf.m, 5.8 ft.lb) Connect the transfer duty solenoid connector.
2. Install a new gasket and the extension case to transmission case. Tighten eleven bolts. Tightening torque: 25 N.m (2.5 kgf.m, 18.1 ft.lb) Adjust the select cable. Refer to «ADJUSTMENT»(ref-208392-S24954581922005120700000) , Select Cable.
3. Install the rear vehicle speed sensor. Tightening torque: T: 7 N.m (0.7 kgf.m, 5.1 ft.lb)
4. Install the transmission rear crossmember. Tighten the bolts. Tightening torque: T1: 35 N.m (3.6 kgf.m, 26 ft.lb) T2: 70 N.m (7.1 kgf.m, 51 ft.lb) Remove the transmission jack.
5. Install the propeller shaft. .
6. Install the front, center rear exhaust pipe and muffler. Except 2.5 L U5 model Refer to «INSTALLATION»(ref-208361-S07815720742005120700000) , Front Exhaust Pipe and «INSTALLATION»(ref-208361-S21912926732005120700000) , Rear Exhaust Pipe and «INSTALLATION»(ref-208361-S41100021962005120700000) , Muffler. 2.5 L U5 model Refer to «INSTALLATION»(ref-208369-S07988211032005120700000) , Front Exhaust Pipe and «INSTALLATION»(ref-208369-S39698120092005120700000) , Rear Exhaust Pipe and «INSTALLATION»(ref-208369-S32210117812005120700000) , Muffler. 3.0 L model Refer to «INSTALLATION»(ref-208386-S00455349232005120700000) , Front Exhaust Pipe and «INSTALLATION»(ref-208386-S39855252692005120700000) , Rear Exhaust Pipe and «INSTALLATION»(ref-208386-S35967598162005120700000) , Muffler.
7. Connect the transmission harness connector.
8. Install the pitching stopper. Tightening torque: T1: 50 N.m (5.1 kgf.m, 37 ft.lb) T2: 58 N.m (5.9 kgf.m, 43 ft.lb)
9. Install the air cleaner case or air intake chamber. (Non-TURBO model) Except 2.5 L U5 model Refer to «INSTALLATION»(ref-208359-S26990629822005120700000) , Air Cleaner Case. 2.5 L U5 model Refer to «INSTALLATION»(ref-208368-S21026510882005120700000) , Air Intake Chamber. 3.0 L model Refer to «INSTALLATION»(ref-208384-S25696994432005120700000) , Air Intake Chamber.
10. Fill with the same amount of ATF that was drained.
11. Check the ATF level. Refer to «AUTOMATIC TRANSMISSION FLUID»(ref-208395-S35776238372005120700000) .

Scheme 525

Scheme 526

Scheme 527

Scheme 528

1. EXCEPT 3.0 L MODEL AND U5 MODEL NOTE: The ATF filter is maintenance free. Lift-up the vehicle. Using ST, remove ATF filter.
2. 3.0 L MODEL AND U5 MODEL ATF Filter NOTE: The ATF filter is maintenance free. Lift-up the vehicle. Remove front left mud guard. Refer to «REMOVAL»(ref-216282-S31390955912006011800000) , Mud Guard. Using ST, remove ATF filter. Get new ATF filter and apply a thin coat of ATF to the oil seal ATF Filter Assembly Remove battery. Lift-up the vehicle. Remove front left mud guard. Refer to «REMOVAL»(ref-216282-S31390955912006011800000) , Mud Guard. Lower the vehicle. Release clamp of IN, OUT of oil filter hose, and remove hose from pipe. NOTE: Plug the pipe. Put a mark etc., to distinguish IN, OUT on pipe and hose. Remove oil filter bracket installation nut. Remove ATF filter assembly. Remove ATF filter with attachment to bracket.

Scheme 529

Scheme 530

Scheme 531

1. EXCEPT 3.0 L MODEL AND U5 MODEL Get new ATF filter and apply a thin coat of ATF to the oil seal. Install ATF filter. Turn it by hand, being careful not to damage oil seal. Using ST, tighten ATF filter to transmission case. Calculate ATF filter torque specifications using the following formula. T2 = L2/(L1 + L2) x T1 T1: 14 N.m (1.4 kgf.m, 10.1 ft.lb) [Required torque setting] T2: Tightening torque L1: ST length 0.078 m (3.07 in) L2: Torque wrench length Example: NOTE: Align ST with torque wrench while tightening ATF filter. ST 498545400 OIL FILTER WRENCH Add ATF. Inspect level of ATF. Refer to «AUTOMATIC TRANSMISSION FLUID»(ref-208395-S35776238372005120700000) .
2. 3.0 L MODEL AND U5 MODEL ATF Filter Get new ATF filter and apply a thin coat of ATF to the oil seal. Install AT oil filter. Turn it by hand, being careful not to damage oil seal. Using ST, tighten AT oil filter to attachment. Calculate AT filter torque specifications using the following formula. T2 = L2/(L1 + L2) x T1 T1: 14 N.m (1.4 kgf.m, 10.1 ft.lb) [Required torque setting] T2: Tightening torque L1: ST length 0.078 m (3.07 in) L2: Torque wrench length Example: NOTE: Align ST with torque wrench while tightening AT oil filter. ST 498545400 OIL FILTER WRENCH Install front left mud guard. Refer to «INSTALLATION»(ref-216282-S08231901382006011800000) , Mud Guard. Add ATF. Inspect level of ATF. Refer to «AUTOMATIC TRANSMISSION FLUID»(ref-208395-S35776238372005120700000) . ATF Filter Assembly Install ATF filter with attachment to bracket. Tightening torque: 14 N.m (1.4 kgf.m, 10 ft.lb) Install ATF filter assembly to vehicle. Tightening torque: 16 N.m (1.6 kgf.m, 12 ft.lb) Install AT oil filter. Turn it by hand, being careful not to damage oil seal. Using ST, tighten AT oil filter to transmission case. Calculate AT filter torque specifications using the following formula. T2 = L1/(L1 + L2) x T1 T1: 14 N.m (1.4 kgf.m, 10.1 ft.lb) [Required torque setting] T2: Tightening torque L1: ST length 0.078 m (3.07 in) L2: Torque wrench length Example: NOTE: Align ST with torque wrench while tightening AT oil filter. ST 498545400 OIL FILTER WRENCH Install hoses to pipe. NOTE: Install hoses to pipe aligning marks on them. Install front left mud guard. Refer to «INSTALLATION»(ref-216282-S08231901382006011800000) , Mud Guard. Add ATF. Inspect level of ATF. Refer to «AUTOMATIC TRANSMISSION FLUID»(ref-208395-S35776238372005120700000) .